Low-Profile Relay Layout With Horizontal Armature Pivot
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Solution Overview
Problem
Existing relays are not sufficiently miniaturized for compact designs while ensuring safe, long-term operation and reliability, especially under vibrations, and are difficult to assemble and adjust.
Innovation Solution
The electromagnetic drive is positioned with the axis of rotation horizontal to the iron core plane, using a rectangular coil with a width at least 1.5 times the height, and an anchor holder with a spring to securely position the armature, along with a positioning pin for precise adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the relay uses a conventional structure with gate-shaped iron core and U-shaped armature, then the relay can achieve basic electromagnetic switching function, but the relay size is too large for compact designs
Solution Approach 1:
The relay is divided into two separate parts: an electromagnetic drive unit with iron core and coil, and a contact unit with contacts and actuating part. These parts are connected through a partition wall, allowing independent optimization of each unit while achieving compact overall size. The segmentation enables the electromagnetic drive to be positioned with horizontal axis of rotation, reducing the relay height.
Solution Approach 2:
The armature rotation axis is changed from vertical to horizontal orientation, parallel to the partition wall. This dimensional change allows the armature to rotate in a plane perpendicular to the iron core, significantly reducing the relay height and enabling more compact packaging of components.
2Volume of moving object
If the relay is miniaturized to reduce size, then compact design is achieved, but assembly and adjustment become difficult
Solution Approach 1:
By separating the relay into electromagnetic drive and contact units that can be assembled on opposite sides of a partition wall, the design allows for modular assembly. Components can be pre-assembled and adjusted independently before final integration, maintaining ease of manufacture despite miniaturization.
Solution Approach 2:
The partition wall acts as an intermediary structure that separates and organizes components on opposite sides. It provides mounting surfaces for both the electromagnetic drive and contact units, facilitating systematic assembly and adjustment while maintaining compact dimensions.
3Ease of manufacture
If the relay structure is simplified to ease assembly, then manufacturing becomes easier, but positional accuracy of armature decreases
Solution Approach 1:
The spring element automatically positions and presses the actuating part against the armature, providing self-aligning and self-adjusting functionality. This elastic pressing mechanism ensures consistent positional accuracy without requiring complex adjustment mechanisms, maintaining both ease of assembly and manufacturing precision.
4Power
If the coil dimensions are changed to optimize magnetic field, then electromagnetic performance improves, but relay height increases
Solution Approach 1:
Changing the armature rotation axis to horizontal orientation and positioning it parallel to the partition wall fundamentally alters the spatial arrangement. This allows the coil to be wound with width greater than height while the overall relay height is reduced, as the magnetic field acts in a different spatial plane.
Solution Approach 2:
Instead of increasing coil height to improve electromagnetic performance, the design inverts the approach by increasing coil width while maintaining reduced height. The horizontal axis of rotation and repositioned components allow the magnetic field to be optimized through width rather than height, achieving both goals simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration results in a more compact, reliable, and easily assembled relay that maintains stability under vibrations and allows for precise positioning of components, ensuring safe and long-term operation.
Implementation Method 1
an electromagnetic drive (13) which can be actuated by a control current and consists of an iron core (21) and a yoke (23) and a coil (37)
Implementation Method 2
which presses the armature (15) onto the yoke (23)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a relay (11) with an electromagnetic actuator (13) comprising an excitation coil (37) arranged around an iron core (21) defining a plane and a yoke (23). The electromagnetic actuator (13) interacts with a movable armature (15) which can switch a movable electrical contact (117) via an actuating arrangement. The relay (11) is housed in a casing (133), with an intermediate floor or partition (17) provided between the electromagnetic actuator (13) and the contact (117). The electromagnetic actuator (13) is located on one side of the partition (17) and the movable electrical contact (117) is located on the other side of the partition (17). The partition (17) has an opening (99) through which the mechanical actuation of the contact is carried out.Because the armature (15) can be pivoted about a rotation axis (55) perpendicular to the plane of the iron core (21), the relay (11) can be built lower than conventional relays.